Validation and calibration apparatus and method for nuclear density gauge

ABSTRACT

A cost effective, field-usable validation and calibration apparatus and method for nuclear density gauges comprises an absorption element, where the absorption element is capable of simulating at least one known density when subjected to analysis using the nuclear density gauge. The absorption element may be positioned inside an enclosure, which also may include an insertion hole capable of receiving a source rod from a nuclear density gauge. The absorption element also can be capable of simulating a plurality of densities, both in backscatter and direct transmission modes. A method of validating and re-calibrating a nuclear density test gauge is also provided, where only a single block of a known density, either a reference block or a field block with a simulated density, is required.

RELATED APPLICATION

This application is a continuation of U.S. patent application Ser. No. 08/873,815 filed on Jun. 12, 1997, now U.S. Pat. No. 5,923,726 which is hereby incorporated herein in its entirety by reference.

FIELD OF THE INVENTION

The present invention generally relates to nuclear density gauges and more specifically to an improved field usable validation and calibration apparatus and method for nuclear density gauges.

BACKGROUND

Compaction measurement is of great significance in the construction of highways, airports, railway embankments, trench backfills, dams and foundations. The knowledge of material density can be a major indicator of how well a resident structure will perform its intended usage. Under compaction can cause serious deformation and settlement of the structure, while over compaction can cause cracks that affect the required material strength. Also, in-place density measurements are necessary to ensure proper testing of asphalt paving used in highways, airports and parking lots. Either by design choice or to comply with standards and/or job requirements, density measurements are used as a field quality control test for monitoring the compaction of soil, asphalt and concrete structures.

Nuclear gauges are the standard method of density measurement in most heavy construction projects. Various State Departments Of Transportation (DOT), as well as the Federal Highway Administration (FHWA), have adopted specifications for use of nuclear density gauges. Nuclear gauges are used to determine compliance with the specification for construction projects. While, there are numerous testing methodologies in use to measure structure density, nuclear testing devices are the preferred standard around the world, due to their speed, accuracy, and convenience.

Older, more primitive testing methods such as sand cone (soils), balloon (soils) and core samples (asphalt) testing are time-consuming and involve taking samples of the test materials off-site for analysis. Results are often not available for as long as 24 hours after sampling, which is especially problematic in asphalt construction projects. These testing processes are labor-intensive and necessarily involve the destruction of small pieces of the structure material. Nuclear gauges, on the other hand, are portable devices which are placed on the material and automatically display the material density in as little as 15 seconds.

Nuclear Density Gauge Theory

Nuclear density gauges operate by using a very small radioactive source and a detection system. When placed on the test material, the photons from the nuclear source penetrate the material. A fraction of the photons will interact with the material and scatter to the gauge base where they are detected by Geiger Mueller detectors. The number of photons scattered back and counted by the detectors is proportional to the material density.

Nuclear gauges can operate in two different modes: backscatter and direct transmission. In the backscatter mode, the gauge is placed on the test material with the source and the detectors in the same plane. The photons from the source penetrate the material from the surface and scatter to the detectors. This mode is normally used for measurement of asphalt and hardened concrete. Hence, no destruction of the test structure occurs. In the direct transmission mode, a hole larger than the diameter of the source rod is formed in the material (normally soils) and the source is inserted into the material at a predetermined depth. In this mode, the material is located directly in the path between the source and the detectors.

Nuclear density gauges are also widely used in the processing industry for measurement of raw material density and automatic control of process operations. Even though the design of the radioactive source material and detectors are different than the ones used in the construction industry, the principles of density measurement are the same as discussed above. Therefore, the teachings of this invention can be used for the calibration validation and calibration of nuclear density devices in all other industries.

Calibration of Nuclear Gauges

As with many testing instruments, calibration is of vital importance for nuclear gauges. Presently, nuclear gauges are calibrated in the factory by using blocks of known density. These blocks are large (i.e. 24"L, 17"W, 14"H) and heavy (360 to 560 lbs). The blocks often consist of metals (i.e. magnesium, aluminum, and/or a combination block of magnesium and aluminum) and natural materials such as limestone and granite. Gauges are placed on these blocks and a "count" is obtained at each depth. Gauge measurements may involve counts obtained at depths of 0 inches (backscatter) to 12 inches (direct transmission), as well as intermediate depths at increments of 0.5, 1 or 2 inches, depending on the gauge design. These counts, along with the known block densities, are used in an equation such as

    CR=A e.sup.(-BD) -C                                        (1)

where:

CR is a count ratio or ratio of gauge count on the test material and a standard count

A, B and C are gauge parameters for each depth

D is the material density

The standard count is collected with the gauge on a small polyethylene block provided with each gauge. The standard count corrects the gauge counts for source decay (i.e. approximately 2.4% each year for Cesium-137) and minor electronic drift. The constants A, B and C are determined by a suitable curve fitting process using mathematical and computer methods well known in the art. These values are entered into the gauge memory for calculation of density in the field. Thus, each gauge receives values for the constants A, B and C for each depth from the factory calibration process.

Field Density Measurements

In the field, a count reading is taken on a test material. This reading is used, along with the A, B, and C constants for each depth and the standard count, to calculate a density using the rearranged equation (1) from above: ##EQU1## Calibration Standards and Requirements

Two ASTM standards that currently require validation of the nuclear gauge calibration are as follows: ASTM standard D2922, "Density Of Soil and Soil-Aggregate In Place By Nuclear Methods (Shallow Depth)" and ASTM Standard D2950, "Standard Test Method For Density Of Bituminous Concrete In Place By Nuclear Methods." ASTM D2922, requires that nuclear gauge calibration be verified at least once every 12-18 months. ASTM D2950 requires a verification of gauge calibration at least once per year. While the standards set forth the intervals for calibration and verification, there is little instruction on how and with what type of device the verification can be performed.

Nuclear gauges are calibrated with large and expensive density standards before leaving the factory. Each manufacturer uses a slightly different calibration method. The calibration is performed to establish the count to density relationship for each unit produced. Calibration enables the gauge to measure field material density.

Gauges are typically used in a very rough construction environment. Presently, two questions are commonly raised regarding the gauge calibration validity. The first question concerns how long a gauge will operate without a need for new calibration. The second question concerns the possible variation in density measurements of two gauges on a given material. The two gauges can be of the same make and model, or from different manufacturers. Without a reliable validation device, it is impossible to determine if one or both gauges require a new calibration. The answer to these questions presently can only be obtained by returning the gauges to the manufacturer or other testing laboratories equipped with calibration standards for verification and calibration of the gauges at all depths of operation. In addition to the costs charged by such entities to perform the new calibration (in effect, a re-calibration), the shipping costs and loss of use (an average of two weeks) can be substantial as well. Therefore, because of the inconveniences of the calibration techniques used today, users and manufacturers have yet to be provided with suitable tools to answer the question of whether and how often their gauge needs calibration. Thus, the absence of suitable validation and calibration techniques have hindered users who desire feedback that they are getting consistent and accurate results.

A small number of gauge owners have used two methods for gauge calibration validation. Some have molded blocks out of concrete for validation purposes. However, blocks made from construction materials are heavy and cannot be transported easily from site to site. Also, the block density can change, due to wear and the degree of moisture absorption over time. This change in block density defeats the usefulness of these blocks, since they cannot be relied on as a fixed density reference to validate the gauge calibration. Also, in some instances, a fixed location is marked on concrete floors or asphalt parking lots for gauge validation. Gauges are placed on this spot from time to time to test the validity of the calibration. The measurements under this condition are affected by the change in the material density over time and limited to the backscatter mode only. Also, validation at one depth cannot be used to predict accurately gauge calibration validity at other depths.

Prior art methods of calibration include those described in U.S. Pat. Nos. 4,587,623 and 4,791,656. U.S. Pat. No. 4,587,623, of which applicant is a co-inventor, uses the constant B from the original factory calibration and actual gauge counts on the magnesium and aluminum standard block to calculate the parameters A and C of equation (1) above. In this process, curve fitting is not necessary. The block densities, the B parameter and the counts can be plugged into the calibration equation and A and C are analytically calculated. The two blocks used for performing this calibration are large, heavy, expensive and not portable.

U.S. Pat. No. 4,791,656, requires the purchase of three blocks. Namely a magnesium block, a magnesium/aluminum (Mg/Al) combination block and an aluminum block. This method relies on the counts obtained from the Mg/Al combination block and historical relationships developed between Mg/Al and magnesium, and Mg/Al and aluminum blocks, of known densities to calculate counts for magnesium and aluminum, at all depths. These three counts are then used with an appropriate fitting routine to determine the parameters A, B and C. The method in the '656 patent requires an initial purchase of three blocks and a collection of data for a predetermined period. The data collected is then used to develop linear relationships between Mg/Al and magnesium, and Mg/Al and aluminum. After a determination of these historical relationships, this method provides an efficient calibration method for the gauge manufacturer. However, it is not a field practical and cost effective solution for the gauge users due to the requirement of multiple reference blocks.

Gauge users need a convenient and portable validation block that can be used as a fixed density reference and one that does not change with time. Also, if it is shown that the calibration cannot be validated, it is desirable to have a simple calibration process so that gauges can be calibrated, without the costly and cumbersome processes of shipping the gauge off-site for calibration.

SUMMARY OF THE INVENTION

A cost effective, field-usable validation and calibration apparatus and method for nuclear density gauges are provided. The apparatus comprises an absorption element, where the absorption element is capable of simulating at least one known density when subjected to analysis using the nuclear density gauge. The absorption element may be positioned inside an enclosure, which also may include an insertion hole capable of receiving a source rod from a nuclear density gauge. The absorption element also can be capable of simulating a plurality of densities, both in backscatter and direct transmission modes. A method of validating and re-calibrating a nuclear density test gauge is also provided, where only a single block of a known density, either a reference block or a field block with a simulated density, is required.

The apparatus and the method described herein provides the industry with a uniform validation method and a calibration method. It will also serve as a field standardization method for gauge density readings taken on a given material for all gauge models regardless of the manufacturer.

These and other aspects of the present invention as disclosed herein will become apparent to those skilled in the art after a reading of the following description of the preferred embodiments when considered with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an elevation view (with partial cut-away) of a nuclear gauge tester.

FIG. 2 is an isometric view of a validation and calibration field test block according to this invention.

FIG. 3 is a cross-section view of a validation and calibration field test block and nuclear gauge.

FIGS. 4A and 4B are cross-sectional top views of an interior view of a validation and calibration field test block showing an absorption element.

FIG. 5 is a cross-section of another embodiment according to this invention.

FIG. 6A is a cross-section of yet another embodiment of this invention.

FIG. 6B illustrates an absorption element according to another embodiment of this invention.

FIG. 7 is a cross section of a field block for use with backscatter tests according to this invention.

FIG. 7A illustrates a field useable instrument used in a backscatter mode according to one embodiment of the present invention.

FIGS. 8A, 8B, and 8C depict flow charts indicating methods according to this invention.

FIGS. 9A, 9B 9C and 9D depict additional flow charts indicating methods according to this invention.

The drawings are for the purpose of describing a preferred embodiment of the invention and are not intended to limit the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 shows a representative nuclear gauge 10. Manufacturers of such gauges include: Humboldt Scientific, Inc. of Raleigh, N.C.; Campbell Pacific Nuclear (CPN) of Martinez, Calif.; Troxler Electronic Laboratories, Inc., of Research Triangle Park, N.C.; and Seaman Nuclear of Milwaukee, Wis. As is well known in this art, a nuclear gauge 10 operates by using a small radioactive source 12 (e.g., Cesium-137) positioned in a source rod 14. Detectors 16 (e.g., Geiger Mueller) are mounted in the base of the gauge as shown. The measurements can be taken from the surface to a depth (i) of 12 inches, and at increments therebetween (e.g., 1 inch increments).

Surface measurements, where i is zero, are referred to as "backscatter." In this mode, the source and the detectors are in the same plane separated by a fixed distance. At depths other than at the surface, such measurements are known as "direct transmission." Thus, "direct transmission" occurs when the source rod is inserted into the test material at depths (i) varying from, for example, 2" to 12" from the surface. The parameters and measurements for each depth are different and must be determined independently.

During testing, a nuclear density gauge is placed on the material 20 sought to be tested. For direct transmission tests, a bore 13 is formed in the material 20 for the insertion of the source rod 14. The radioactive source in the source rod emits photons, which penetrate the material. Photons from the nuclear source interact with the material and a fraction will scatter to the detectors 16 in the gauge base. Representative photon paths 18 are shown in FIG. 1. Electronics and a display 22 capable of performing calculations are also contained within the gauge.

The number of photons scattered back to the detectors is proportional to the material density. In the density range (approximately 1600 kg/m3 to 2700 kg/m3) of construction materials, the higher the material density the lower the detected counting rate of the gauge.

FIG. 2 depicts one embodiment of a representative portable, light weight, in-field calibration and verification block 30 (hereinafter may be referred to as "field block") according to this invention. In a preferred embodiment, the field block is approximately 10" in width, 14" in length, and 14" in depth. However, the shape of the block is not limited to the shape shown. Other block configurations with different dimensions and geometrical shapes can also be used with different design and operating modes of the gauge that will allow this invention to be practiced as well. Carrying handles 33, or other suitable means to allow for easy movement, also are provided for the operator to lift and transport the unit to and from the field. Other means for transporting the field block include carrying straps, handles formed within the walls of the block, separate carrying case or bag, carrying cart, casters designed into the block, integrated handle and wheel design, and the like.

An insertion tube 32 can be positioned in the top of the block, extending downward into the block. In a preferred embodiment, the tube 32 has a diameter of approximately 1" and is located approximately 2" in from one edge of the block. An insertion tube 32 is not required if the field block is intended for use only in backscatter modes. For this type of an embodiment, the overall dimensions can be different, e.g., 16 inches length by 10 inches width and 5 inches in height.

FIG. 3 shows a cross-sectional view of a field block 30 according to one embodiment of this invention. Lead or other suitable bottom and side shielding liner 34 is placed within the walls 35 of the block. An absorption element 36, constructed of lead or other suitable material, is positioned inside the block within the radiation path of the gauge to simulate one or more fixed densities at different depths i. Top liner 31 serves the dual purpose of shielding the user from radiation, as well as acts as an absorber, which will influence the ability of the block to simulate densities. Using this construction, density ranges of standard construction materials (1600 to 2700 kg/m3) can be achieved by placing varying amounts of lead or other material in the radiation path of the gauge. In this manner, blocks of any desired density can be simulated.

In a preferred embodiment, the field block 30 comprises an enclosure, such as an aluminum sheet metal (1/8" thick) hollow enclosure, with a length of 14", width of 10", and height of 14". This block can be wrapped on the inside or outside of all surfaces of the enclosure with a 0.005" layer of lead sheet 34 for shielding the gauge operator from the nuclear source. In addition to aluminum, those skilled in the art will realize that the enclosure can be designed from plastic sheets, Plexiglas, molded material, wood or other materials suitable for field and laboratory use.

The block 30 can have an insertion tube 32 with a diameter of 1" to accommodate positioning the source rod at different depths in the enclosure. A 1.25" by 1.25" lead absorption element 36 with a thickness varying from 0.1" to 7" can be positioned adjacent the insertion tube 32, in the radiation path, at different depths. Those skilled in the art understand that other materials with high density such as Tungsten, Cadmium, etc., can be used. Moreover, it is not necessary that the absorption element 36 be comprised of the same material; combinations of materials can be used as well. The absorption element 36 is placed in the radiation path between the source 12 and detectors 16 to create blocks that would simulate different densities.

FIG. 4A shows a cross-sectional view within the block, taken along lines 4A--4A from FIG. 3. As shown in FIGS. 3 and 4A, the absorption element 36 in this embodiment increases in thickness with increasing depths i. A retainer cylinder 37 also is shown, surrounding the tube 32 and supporting the absorption element 36. As the insertion depth (i) of the source rod 24 increases, a large proportion of the detected photons will have higher energies. To reduce the number of high energy photons, more lead is needed to decrease the number of counts and thus to simulate the same densities as the lower source depth settings. To simulate higher densities, relatively more lead has to be used at greater depths in the block 30.

High density materials such as lead, tungsten, cadmium and other heavy elements are ideal as shielding materials for gamma rays, and thus are appropriate absorption elements. Such materials can be used individually or in combination with each other or other materials. The measurement of density by nuclear gauges is based on the detected counts from the test material. The magnitude of the detected counts depend on scattering and absorption proportions from the material. This proportion depends on the density of the material. Generally, an increase in material density causes higher absorption (photons are lost) and fewer detected scattering events. Therefore, with higher density materials, the gauge detected counts are lower than low density materials.

With this understanding of the photon absorption and scattering principles, one can simulate different density blocks by placing high density "filters" or absorption elements in the path of the radiation between the source and detectors. These "filters" cause absorption and allow sufficient photons to pass to the detectors to simulate a count similar to the counts collected on a known density reference. In a preferred embodiment, lead filters are used, having a density of approximately 11.34 g/cm3. Lead of differing thickness is used in the path between the source and the detectors, at each depth i, to simulate and achieve the same count on the gauge as what would be observed by the same gauge from a reference block of known density. Those skilled in the art can use the methods of this invention to place absorber materials of appropriate thickness in different locations in the radiation path between the source and the detectors to create an optimum field block for the density range of interest.

A total weight of a field block according to this invention can be approximately 12 kg (27 pounds). The block is light weight, convenient and can easily be transported manually by the gauge operator or on a truck for immediate use as a calibration validation indicator or, with an appropriate method, as a tool for generation of new calibration. The lead thickness necessary to simulate a density within the calibration range of the block is determined by using a gauge accurately calibrated on a set of known density reference blocks. This gauge is used on the field block and readings are taken with different thickness of lead until the desired density or count reading on the gauge is achieved.

In another embodiment, a field block with the density of magnesium (approximately 1.77 g/cm3) can be constructed. Using a magnesium block, an accurately calibrated gauge may obtain a certain count, e.g., 3000 counts. The same gauge is then placed on the field block and enough filter (e.g., lead) is placed in the radiation path between the source and the detectors to absorb the required number of photons to produce 3000 counts. Therefore, in this example, one can mark this field block to have the same density as magnesium when measured with the above gauge type. The same procedure can be followed for each source depth to determine a simulated block density based on an accurately calibrated gauge.

In alternative embodiments, the absorption elements can be used in different configuration, sizes and geometries at different locations in the radiation path between the source and the detector to produce the same density effect as the one described in the above embodiment. For example, FIG. 4B depicts an alternative geometrical configuration of a flared absorption element 41. Here, the element is rotatably mounted on a cylinder 39 forming an insertion tube. The mounting can occur through mechanical attachment means 35, or other suitable techniques well known in the art. The absorption element has a constant cross-section over the entire length of the insertion tube. During use, the cylinder 39 and absorption element 41 is rotated in the direction shown to obtain desired simulated densities. In one embodiment, the shape of the flared absorption element widens from 0 inches thickness at a theta (θ) angle of about 25 degrees and depth of 2" to approximately 2.95" thickness at a theta (θ) angle of about 180 degrees and depth of 12". Using lead as the absorber, this configuration will yield a simulated density reading. The flared absorption element is moved into an appropriate depth and/or position and angle in front of the source by either using a motorized means or manually by utilizing a handle or a lever capable of positioning the flared filter element into the radiation path between the source and the detectors.

FIG. 5 shows another embodiment of this invention. In this field block 50, the insertion for the source rod consists of a 1" hole 52 to allow the penetration of the source rod 14 into a direct transmission position. The absorption material 36 is positioned on a support 54, which is translationally mounted to the enclosure 53. The mounting means can be any mechanical or electronic positioning apparatus that allows the support 54 to move in the X direction, as shown in FIG. 5. For example, a threaded rod 56 with accompanying dial 57 and metering plate 51 can be placed in a threaded opening 58 of the support structure, allowing the user to move the absorption element 36 to a desired set position within the enclosure 53. To facilitate ease of movement of the support 54, the support can be mounted on rollers 58, moving within guides 59. In this manner, the absorption element 36 can be placed at different distances from the hole 52 and source rod 14. Such variances can affect the simulated densities of the field block, since the geometry of the absorption element within the radiation path between the source and the detectors is unchanged. Hence, multiple simulated densities are possible within the same field block 50. The field block can be calculated using an accurately calibrated gauge and positioning the element 36 at different locations with respect to the source rod 14. The user will then be supplied with calibration figures, such as the following:

    ______________________________________                                         Simulated Density at 6                                                         inches depth     Dial Position                                                 ______________________________________                                         2200 kg/m.sup.3  1                                                             2100 kg/m.sup.3  5                                                             2000 kg/m.sup.3  10                                                            1900 kg/m.sup.3  15                                                            1800 kg/m.sup.3  20                                                            ______________________________________                                    

During calibration the figures in the first column above would be obtained using a nuclear gauge of known calibration. During use in the field, the user would turn the threaded rod 56 until the dial was pointed to the desired position on the metering plate 51. A suitable locking mechanism, which could be built into the rod 56/dial 57 and/or roller/guide assembly, can be included to ensure that the rod 56 and element 36 do not move during testing, after the desired location has been obtained. It is also possible to control the process by programmable controls from a computer or other electronic device.

FIGS. 6A and 6B show yet another embodiment. A cross-sectional view of a field block 60 is shown in FIG. 6A. An optional insertion hole 62 is placed in the top of the block, allowing for the insertion of a source rod (not shown). A support 64 is slidably mounted within the block, on guides 66. An absorption element 68 is positioned on the support 64, and can be placed at a designated height on the support 64, within the field block. In this manner, the absorption element 68 is placed in the radiation path between the source and detectors to simulate at least one density at each source rod setting.

The support 64 is removable from the field block through a door 70, shown at the rear of FIG. 6A. The door 70 is mounted by hinges 72, and secured through a closure 74.

FIG. 6A shows an alternative support 76, with absorption element 78. Element 78 is located at a different depth on the element 64, and can be of a different thickness to achieve the same or a different simulated density when placed in the field block. Elements are changed by opening the access door 70, sliding the existing support 64 out of the field block, and then placing the support 76 in the field block, along the guides 66.

Each support, 64 and 76 actually can serve as two different simulated densities by merely removing the element, inverting it, and replacing the element in the field block. Hence, the support 76 could function with an absorption element 78 located at a 4 inch height, as shown in FIG. 6B, or the same element positioned at a depth of 8 inches when inverted.

Each such support/absorption element assemblies as shown in FIGS. 6A and 6B will have sufficient and different thickness of absorber material as determined by an accurately calibrated gauge to simulate at least one density.

FIG. 7 shows another embodiment that does not use an insertion hole or tube. For nuclear density gauges that do not have direct transmission measurement capabilities, and are intended only for backscatter measurements, insertion holes are not needed. Hence, a field block 80 is provided, which has an optional surrounding shield 82 about an enclosure 84. Handles 86 are provided for ease of carrying. An absorption element 88 is positioned within the field block, yielding a simulated density. Of course, any of the other embodiments discussed above, minus the insertion hole, can also be adapted for a field block 80. For example, the absorption element 88 could be placed on a translational, threaded rod assembly to simulate multiple densities for a backscatter testing application. The element 88 can be moved in the X or Y directions as shown to simulate multiple densities.

Combined with appropriate software running the methodology as discussed below, and a personal computer (PC), or other electronic devices with computation capabilities such as held calculators, hand held portable scalars, or gauge internal processors, this product can display the calibration validation readings at different densities and generate new calibration constants at different gauge depths. For field use, an optional hand held programmable scalar or calculator can also be provided to allow the users access to the same information available on the PC program. Also, the process of validation and calibration described in this disclosure can be carried out in the field by programming the processor/computer in the nuclear gauge itself to allow even easier access to this method by the users.

Calibration Validation and Calibration Method

It is well known to those skilled in the art that gauge calibration can change with time due to several factors. Factors affecting gauge calibration include radioactive source decay, change in mechanical geometry such as deterioration of material, expansion of metals, bending of critical parts, movement of detectors, or other components, change in the detector efficiency over time (varies with amount of gauge usage), and electronic drift. Some of these changes are accounted for in the density calculation process of the gauge. The count ratio (gauge counts/std. count) corrects for source decay and minor electronic drifts over time. However, since the measurement geometry is significantly different in the gauge standard count position as compared to the actual test counts, other affects on the gauge calibration such as detector efficiency, mechanical geometry and major electronic component drifts can cause significant change in the gauge measurements. Thus, a new calibration is required due to the above factors and changes.

In a preferred embodiment, a block of predetermined density is used to calculate changes to the gauge counts due to decay factor (DF) and geometry factor (GF). GF is defined as the total of all effects not including the radioactive source decay. Once the factors affecting the gauge calibration are quantified, the gauge calibration validation can be tested and, if necessary, re-calibrations can be performed.

In this invention, a portable field block is used for calibration validation and new calibration. However, those skilled in the art will appreciate the fact that any block with a known density can be used with the teachings of this invention for the determination of gauge calibration validation and new calibration at all depths and modes of operation.

Validate The Gauge Calibration

Once an appropriate density is assigned to the field block as discussed above, it can be used for validation of gauge calibration. Validation is performed as follows:

Place the nuclear gauge on the field block (or place the field block in the measurement zone of the gauge).

Take gauge readings at all operating positions or modes of the gauge.

Compare the gauge density measurements to the assigned density values of the field block for all the positions and modes of measurement.

If the absolute value of the % error between the gauge density readings and the assigned field density is above a predetermined value, for example 1%, then the gauge calibration is outside the required limit and a new calibration needs to be performed on the gauge.

Where,

% error=[(Field block density-Gauge measured density)/(Field block density)]*100

Note: The error limit acceptable to the user depends upon the user's testing procedures and requirements.

Validate The Gauge Calibration For Differing Densities

A further embodiment of this invention relates to validating the gauge operation at different densities within the density measurement range of interest. For example, in the construction industry, an asphalt density might be between 2.3 g/cm³ to 2.4 g/cm³. If the field block density is below this range, for example 1.92 g/cm³, the user might want to know if the gauge calibration is accurate not only at 1.92 g/cm³ but at several densities between 2.3 g/cm³ and 2.4 g/cm³. In this case, the gauge counts on the field block, the field block density and the gauge calibration can be used to accomplish this task, as set forth below. The validation and calibration method described in this disclosure requires the gauge to have been calibrated at the factory at least once. The factory calibration parameters are used throughout this method for calibration validation and for generating new calibrations.

In a preferred embodiment, software is provided to allow the input, recordation and calculation of desired parameters. FIGS. 8A through 8C illustrate the methodology employed in a preferred embodiment.

As shown in FIG. 8A, in Step 102, specific gauge factory calibration data is entered into the computer program. Such gauge data can include the gauge model, gauge serial number, gauge calibration date, gauge calibration constants (A, B and C) for depths of 0 through 12 inches, etc. Next, the simulated field block density (FBD_(i)) for i=0 to 12" depth is entered in Step 104. In 106, a gauge reading of the standard count (Dstd) is taken on the reference block provided with the gauge. The date that the readings are being taken is entered at Step 108.

In Step 110, take counts (ROi) and densities D1i measured by the gauge, for i=0 to 12" depth on the field block.

At this point, the operator can compare the density readings displayed on the gauge (Step 110) versus the density provided for each depth for the field block (entered in Step 104) and determine if the readings are within the acceptable range of errors, as described in the last section (e.g., within ±1%). Alternatively, software can calculate the % error in the readings, as set forth below.

Step 112: Calculate the elapsed time (Te) in number of days from the gauge's calibration date and the day of measurements.

Te=(Calibration date-Test date) Step 114: calculate the decay factor, DF

DF=exp(-λ*Te)

where

λ=decay constant (e.g., 0.693/T_(1/2)), and T_(1/2) is the half life of the source (e.g., 30 years for Cesium-137), defined as the period during which the activity of the source falls by a factor of two

Te=elapsed time in days from the calibration date

Step 116: Using the field block density provided (FBD_(i)) for i=0 to 12" depth in Step 104, the gauge calibration constants A_(i), B_(i) and C_(i) in Step 102 and the daily reference standard count (Dstd) from Step 106, calculate what the field block counts would have been, if they were taken on the day of gauge calibration, in accordance with the following formula:

    R1i=Std*A.sub.i *exp (-B.sub.i *FBD.sub.i)-C.sub.i

for i=0 to 12"

Step 118: Based on the elapsed time calculated in Step 112, correct the R1i counts for decay using the decay factor in 114 with the following formula:

    R2i=R1i*DF

Thus, R2i is the theoretical count for the field block as if the change in gauge counts from the day of calibration was only due to decay of the radioactive source. Other changes in counts can also occur with the passage of time due to changes in detector efficiency, change in gauge mechanical geometry and change in the electronic components of the gauge.

Step 120: To Calculate the total affect of other change factors (geometry factor GF) on the gauge, R0i and R1i counts, for i=0 to 12" depth, should be compared

    GF=(R0i-R2i)/R0i

Validation of Gauge at Multiple Desired Densities

FIG. 8B illustrates the method by which a field gauge is validated at multiple desired densities.

Step 300 : Select desired densities Dij at which calibration validation is desired. The densities Dij are selected at each gauge depth i=1 to 12" and density increments of j=1 to ∞ within the range of the gauge calibration.

Step 304: Based on the gauge calibration parameters and selected densities D_(ij) calculate counts C_(ij). Where, i=0 to 12" and j=1 to ∞ number of density increments, according to the following formula:

    C.sub.ij =Std*A.sub.i *exp (-B.sub.i *D.sub.ij)-C.sub.i

where, std. is the factory standard count.

Step 308: Correct counts Cij in Step 304 for decay

    CDij=Cij*DF

Step 312: Correct the CD_(ij) values in Step 308 by Geometry Factor (GF) as follows:

    CCij=CDij*(1+GF)

This will insure that these counts are corrected for all the changes (decay, electronic and mechanical) in the gauge, since the day of calibration.

Step 316: Use the corrected counts from Step 312 and the calibration constants Ai, Bi, Ci and Dstd (from Step 106) to calculate density values DDij as follows:

    DDij=(1/Bi)*1n(Ai/Crij+Ci)

where, Crij is the count ratio (CCij/Dstd).

Step 320: Calculate % error (Eij) by

    Eij=100*((Dij-DDij)/Dij)

Step 324: If the absolute value of Eij is 1% or less, the user likely can continue using the gauge with confidence that the unit has an adequate calibration. This percentage can be determined by the user depending on the level of accuracy required.

Those skilled in the art are not limited to the use of this field block merely to validate a previous calibration. A new calibration may also be obtained, as outlined below.

Calibration Process

To establish a new calibration, the gauge must have had at least one previous calibration. Gauges are always calibrated by the manufacturer before shipment to the customer. Gauges are calibrated by using sufficient number of counts and density pairs to determine the factory calibration equation constant parameters. In this case, equation (1) has constant parameters A, B and C for each depth. Therefore, three counts and density pairs are required to determine the parameters A, B and C by an appropriate fitting routine.

This invention provides a method by which the gauge can be calibrated after validation has failed. However, the calibration process in this invention can be performed without initially performing the validation process. The calibration process is done by using the counts and density of the field block to quantify changes in the gauge counts since the day of factory calibration (e.g., DF and GF of Steps 114 and 120, respectively). Based on these factors, sufficient corrected counts for given densities are calculated using the original factory calibration of the gauge. These counts and the corresponding densities are then used to calculate the factory calibration equation constant parameters.

FIG. 8C illustrates the method of calibration according to an embodiment of this invention. Those skilled in the art can use the teachings of this invention with counts obtained with one block of known material and gauge's factory calibration to generate new calibrations for different calibration ranges within the original calibration range of the gauge. The steps of FIG. 8C are discussed below.

Step 500: If new calibration is desired, select at least three count and density pairs.

Step 504: To comply with the method originally used by the gauge manufacturer for the gauge, select the densities at which the gauge was originally calibrated.

Step 508: Calculate the corresponding counts for the densities selected in Step 504. These counts are calculated in the same manner as Step 304 (i.e. Cij).

Step 512: Correct the counts in Step 508 by the decay factor DF of Step 114.

Step 516: Correct the counts in Step 512 by the geometry factor, GF, of Step 120.

Step 520: Calculate Count ratios by dividing the counts in Step 512 by the daily std count Dstd. of Step 106.

Step 524: Use an appropriate computer fitting routine to determine the parameters A,B and C.

Step 528: Enter the constants A, B and C into the gauge electronics for automatic calculation of density from field measured counts.

FIGS. 9A, 9B, 9C and 9D illustrate some of the methods used in this invention to accomplish nuclear gauge validation and calibration with either the field block and/or other blocks of known density.

In FIG. 9A, a field block is first constructed 1010 as described herein. Next, the simulated densities are established 1012 for the block using an accurately calibrated nuclear gauge. With assignment of the density, the field block can be used for the validation and/or calibration of the gauges used in the field as described in this invention. Next field block counts are taken 1014 using the nuclear density gauge of interest. The user has the option of either validating 1016 the gauge at the field block density, or validating 1018 the gauge at multiple desired densities (see FIG. 8B and accompanying discussion). From either method, the test result error percentages are then calculated 1020. If the error percentages are within acceptable tolerances, the user can continue to use the gauge 1024. If not, the gauge should be re-calibrated 1022 as described herein.

FIG. 9B illustrates that the validation 1042 and/or the calibration 1044 process can be carried out in the field 1040. It is not necessary to validate the gauge prior to calibration. Each process can be performed independent of the other.

FIG. 9C illustrates steps that are analogous to those outlined in FIG. 9A. The difference is that a field block with simulated densities is not used. Instead, counts are taken 1060 on any block of known density. This could be a reference block supplied by the gauge manufacturer, or maintained by the gauge user. Once the counts are taken, the gauge can be validated at the reference block density 1062, or at multiple desired densities 1064 using the methods described above. Error results are evaluated 1066, leading to continued use of the block 1070, or re-calibration 1068. This example illustrates that, although the field block provides a convenient method of measurement, other blocks of known density can be employed for carrying out gauge calibration and/or validation.

FIG. 9D illustrates steps analogous to those outlined in FIG. 9B. The only difference is the block used in collecting the gauge counts for the validation and/or the calibration process. Any block of known density can be used to accumulate the counts necessary to carry out the validation and/or the calibration process described in this disclosure. Counts are taken on the block of known density 1080. Then, the user can elect to either validate 1082 and/or calibrate 1084 as discussed above.

EXAMPLE

The following example further illustrates an embodiment of this invention.

    ______________________________________                                         Enter Gauge Factory Calibration Information (Step 102)                         ______________________________________                                         Gauge Model         3430A                                                      Gauge Serial Number 19509                                                      Mag Density (Kg/m3) 1760                                                       Mag/Alum Density (Kg/m3)                                                                           2137                                                       Alum Density (Kg/m3)                                                                               2598                                                       Calibration Standard Count                                                                         2857                                                       Gauge Calibration Date                                                                             2/6/91                                                     ______________________________________                                         Enter Gauge Factory Calibration Constants                                      Depth   A             B*1000  C                                                ______________________________________                                         0       4.303         1.41163 -0.09956                                         2       13.404        1.28369 -0.17015                                         4       17.545        1.40344 -0.12253                                         6       19.02         1.55169 -0.06347                                         8       22.338        1.85218 -0.05216                                         ______________________________________                                         Enter Field Block Density (Step 104)                                           Depth                 FBDi                                                     ______________________________________                                         0                     1922                                                     2                     1922                                                     4                     1922                                                     6                     1922                                                     8                     1922                                                     Daily Standard Count(Step 106)                                                                              2808                                              Valid./Calib. Date(Step 108) 7/27/94                                           ______________________________________                                         Counts Collected on the Field Block (Step 110)                                 Depth              R0i    D1i                                                  ______________________________________                                         0                   933   2067                                                 2                  3357   2002                                                 4                  3373   1987                                                 6                  2632   1985                                                 8                  1754   1978                                                 Elapsed Time, Te (Step    1251                                                 112)                                                                           Decay Factor, DF (Step 114)                                                                              0.92286                                                                        4                                                    ______________________________________                                         Correct For Source Decay DF and Calculate Geometry Factors DF                  Step 116 Step 118 Step 120                                                     Depth    R1i          R2i    GF                                                ______________________________________                                         0        1100         1015   -0.0879                                           2        3734         3446   -0.02657                                          4        3728         3440   -0.01987                                          6        2935         2709   -0.02909                                          8        1964         1813   -0.03345                                          ______________________________________                                         Select Densities to Check Validation (Kg/m3), Dij (Step                        ______________________________________                                         300)                                                                           1700 1800    1900    2000  2100  2200  2300  2400                              ______________________________________                                         Calculate Counts at Desired Densities, (Steps 304, 308 and 312)                Depth 1700   1800   1900 2000  2100 2200  2300 2400                            ______________________________________                                         0     1158   1037    931  840   760  691   631  579                            2     4243   3783   3379 3024  2711 2436  2195 1982                            4     4411   3875   3408 3003  2650 2344  2078 1846                            6     3582   3090   2669 2308  1999 1735  1509 1315                            8     2531   2125   1788 1508  1275 1082   921  787                            ______________________________________                                         Calculate Gauge Densities (kg/m3), DDij (Step 316)                             Depth 1700   1800   1900 2000  2100 2200  2300 2400                            ______________________________________                                         0     1857   1962   2069 2176  2284 2394  2506 2620                            2     1793   1895   1996 2098  2200 2303  2405 2508                            4     1777   1878   1979 2080  2182 2283  2385 2487                            6     1774   1875   1976 2076  2177 2278  2380 2481                            8     1765   1866   1967 2068  2169 2271  2373 2475                            ______________________________________                                         Calculate % Error in Desired Densities and Calculated Gauge                    Densities, Eij (Step 320)                                                      Depth 1700   1800   1900 2000  2100 2200  2300 2400                            ______________________________________                                         0     -9.23  -9.02  -8.87                                                                               -8.80 -8.78                                                                               -8.84 -8.96                                                                               -9.15                           2     -5.50  -5.27  -5.08                                                                               -4.91 -4.77                                                                               -4.66 -4.58                                                                               -4.51                           4     -4.54  -4.34  -4.16                                                                               -4.01 -3.88                                                                               -3.78 -3.69                                                                               -3.62                           6     -4.37  -4.16  -3.98                                                                               -3.82 -3.68                                                                               -3.56 -3.46                                                                               -3.38                           8     -3.84  -3.67  -3.52                                                                               -3.40 -3.30                                                                               -3.22 -3.16                                                                               -3.12                           Caution: Errors Above 1%, Gauge Failed Validation, (Step                       ______________________________________                                         324)                                                                           Generate New Calibration Constants                                             Select Densities, (Step 504)                                                   ______________________________________                                         Mag Density(Kg/m3) 1760                                                        Mag/Alum Density(Kg/m3)                                                                           2137                                                        Alum Density(Kg/m3)                                                                               2598                                                        ______________________________________                                         Calculate Counts For Mag, Mag/Alum and Alum Blocks, (Steps 508, 512,           516)                                                                           Depth     Alum          M/A    Alum                                            ______________________________________                                         0         1310           887    599                                            2         4487          2951   1850                                            4         4592          2848   1658                                            6         3724          2154   1146                                            8         2601          1368    668                                            ______________________________________                                         Calculate Count Ratios, CRij (Step 520)                                        CR1            CR2      CR3                                                    ______________________________________                                         0.392694       0.265893 0.17956                                                1.435499       0.944096 0.591859                                               1.479199       0.917412 0.534084                                               1.188311       0.687331 0.365683                                               0.82624        0.436522 0.213156                                               ______________________________________                                         Curvefit To Obtain the Gauge Constants, (Step 524)                             Depth   A             B*1000   C                                               ______________________________________                                         0       3.668254      1.408753 -0.08516                                        2       12.25163      1.283691 -0.15552                                        4       16.147        1.40344  -0.11277                                        6       17.33993      1.551693 -0.05787                                        8       20.36426      1.852181 -0.04755                                        ______________________________________                                    

The calculations performed in the above example can be performed in any standard spreadsheet or other computer program. The software can be written to be operable in a WINDOWS environment, with appropriate user interfaces and prompts. The calculations referenced herein, for example, can be performed using MICROSOFT EXCEL V. 7.xx. The curve fitting method referenced in Steps 524, 1022, 1044, 1068, and 1084 of FIGS. 8C, 9A, 9B, 9C and 9D can be performed using the SOLVER function, within the TOOLS menu of EXCEL.

The above description of the preferred embodiments thus detail many ways in which the present invention can provide its intended purposes. While several preferred embodiments are described in detail hereinabove, it is apparent that various changes might be made without departing from the scope of the invention, which is set forth in the accompanying claims. 

I claim:
 1. A field block for use with a nuclear density gauge comprising an absorption element, wherein said absorption element is capable of simulating at least one known density when subjected to analysis using the nuclear density gauge, and, wherein the nuclear density gauge comprises a source rod and detector and said field block is configured to receive said source rod therein, and wherein in operation when subject to analysis using the nuclear density gauge, said source rod and said detector define a detection radiation path having an associated spatial volume therebetween, and wherein said absorption element is configured to extend about a portion of the radiation path to thereby leave a remaining portion of the radiation path free.
 2. A field block according to claim 1, wherein said absorption element is mounted to said field block such that it is translatable from a first operative position to a second operative position.
 3. A field block according to claim 2, wherein the nuclear density gauge will perceive two simulated density readings, one corresponding to said absorption element positioned in said first operative position and the second corresponding to said absorption element positioned in said second operative position.
 4. A field block according to claim 3, wherein said translatable positions are at substantially the same depth in said field block, the translation of said absorption element thereby providing two different simulated material density readings at a single source depth.
 5. A field block according to claim 2, wherein said absorption element is rotatably mounted within said field block to rotate said absorption element such that it presents a first profile in the radiation path in the first operative position and a second profile in the radiation path in the second operative position.
 6. A field block according to claim 5, wherein said rotation is in response to a motorized input.
 7. A field block according to claim 5, wherein said rotation is in response to manual movement of a lever.
 8. A field block according to claim 2, wherein said absorption element is linearly translatable within said field block along the radiation path.
 9. A field block according to claim 8, wherein said linear translation is in response to rotation of lever mounted on said field block such that it is externally accessible.
 10. A field block according to claim 1, wherein said remaining free portion of the radiation path is a major portion of the spatial volume extending within said field block between the source rod and the detector.
 11. A field block according to claim 1, wherein said absorption element is configured within said radiation path such that an air gap space extends proximate to each side of said absorption element within said field block along the radiation path.
 12. A field block according to claim 1, wherein said absorption element is mounted within said field block to present a first profile in a first radiation path in a first operative position and a second profile in a second radiation path in a second operative position.
 13. A field block for use with a nuclear density gauge comprising an absorption element, wherein said absorption element is capable of simulating at least one known density when subjected to analysis using the nuclear density gauge, wherein said field block further comprises an enclosure, and wherein said absorption element has an outer surface contour, and wherein said enclosure is substantially hollow and has an inner surface contour, and wherein said enclosure inner surface contour is dissimilar to said absorption element outer surface contour.
 14. A field block according to claim 13, wherein the nuclear density gauge comprises a source rod and detector, and wherein in operation when subject to analysis using the nuclear density gauge, said source rod and said detector define a radiation path therebetween, and wherein said absorption element is configured and sized to be discontinuous in the radiation path.
 15. A field block according to claim 13, wherein said absorption element is mounted to said field block such that it is translatable from a first operative position to a second operative position.
 16. A field block according to claim 15, wherein the nuclear density gauge detects two simulated density readings, a first reading corresponding to said absorption element positioned in said first operative position and a second reading corresponding to said absorption element positioned in said second operative position.
 17. A field block according to claim 16, wherein said first and second operative positions are at substantially the same source depth in said field block, the translation of said absorption element thereby providing two different simulated material density readings at a single source depth.
 18. A field block according to claim 16, wherein said enclosure inner surface contour and said absorption element outer surface contour are configured in spaced-apart relationship to define a major air space volume therebetween.
 19. A field block according to claim 16, wherein said dissimilar enclosure inner surface contour and absorption element contour are configured such that an air gap volume extends within said field block to define a void space proximate the perimeter of said absorption.
 20. A field block according to claim 19, wherein said absorption element is linearly translatable within said field block along the radiation path.
 21. A field block according to claim 20, wherein said linear translation is in response to rotation of a lever attached to said absorption element and mounted on said field block such that it is externally accessible.
 22. A field block according to claim 13, wherein said field block includes a radiation path extending between the detector positioned on an upper surface of said enclosure and the source rod longitudinally extending within said enclosure such that it is transversely and longitudinally spaced apart from the detector, wherein said absorption element has a first profile in a first radiation path corresponding to a first operative position and a second profile different from said first profile in a second radiation path corresponding to a second operative position.
 23. A field block according to claim 22, wherein said absorption element profile which is presented to the radiation path changes as said absorption element translates within said enclosure corresponding to the first and second operative positions.
 24. A field block according to claim 23, wherein said absorption element is rotatably mounted within said field block to rotate said absorption element such that it presents the first profile in the radiation path in the first operative position and the second profile in the radiation path in the second operative position.
 25. A field block according to claim 24, wherein said rotation is in response to a motorized input.
 26. A field block according to claim 24, wherein said rotation is in response to manual movement of a lever attached to said absorption element.
 27. A field block according to claim 22, wherein said absorption element profile which is presented to the radiation path changes while said absorption element remains substantially stationary within said enclosure.
 28. A field block for use with a nuclear density gauge having a source rod and a detector, said field block comprising an absorption element and an upper support platform having opposing outer and inner surfaces defining a thickness therebetween, wherein said absorption element is capable of simulating at least one known density when subjected to analysis using the nuclear density gauge, and wherein, in position for operation, the nuclear density gauge is supported by said field block upper support platform surface, and the source rod and detector define a detection radiation path having an associated spatial volume therebetween, and wherein said absorption element is configured to extend about a portion of the radiation path to thereby leave a major portion of the radiation path free.
 29. A field block according to claim 28, wherein said major free portion includes an air space extending between the upper platform inner surface and the outer contour of said absorption element.
 30. A field block according to claim 28, wherein said absorption element is mounted to said field block such that it is translatable from a first operative position to a second operative position.
 31. A field block according to claim 28, wherein the nuclear density gauge detects two simulated density readings, a first reading corresponding to said absorption element positioned in said first operative position and a second reading corresponding to said absorption element positioned in said second operative position.
 32. A field block according to claim 30, wherein said first and second operative positions are at substantially the same depth in said field block, the translation of said absorption element thereby providing two different simulated material density readings at a single source depth.
 33. A field block according to claim 28, wherein said absorption element has an outer surface contour, and wherein said absorption element contour and said platform inner surface are configured in spaced-apart relationship to define a major air space volume therebetween.
 34. A field block according to claim 33, wherein said upper support platform is provided by the upper portion of an enclosure, and wherein the upper portion of the field block enclosure and said absorption element contour define an air gap volume therebetween which extends proximate to a major portion of the perimeter of said absorption element within said field block.
 35. A field block according to claim 28, wherein said field block includes a radiation path extending between the detector positioned on an upper surface of said platform and the source rod longitudinally extending within said field block and transversely and longitudinally spaced apart from the detector, wherein said at least one air gap volume is configured to extend around the portion of the perimeter of said absorption element which is positioned in the radiation path.
 36. A field block according go claim 35, wherein said absorption element has a perimeter portion with a profile which is presented to the radiation path, and wherein said profile changes as said absorption element moves from one operative position to another.
 37. A field block according to claim 36, wherein said absorption element is rotatably mounted within said field block to rotate said absorption element such that it presents a first profile in the radiation path in the first operative position and a second profile in the radiation path in the second position.
 38. A field block according to claim 37, wherein said rotation is motorized.
 39. A field block according to claim 37, wherein said rotation is in response to movement of an externally accessible manual lever in communication with said absorption element within said field block.
 40. A field block according to claim 28, wherein said absorption element is linearly translatable within said field block along the radiation path.
 41. A field block according to claim 40, wherein said linear translation is in response to rotation of a lever attached to said absorption element and mounted on said field block such that it is externally accessible.
 42. A field block according to claim 41, wherein said linear translation is motorized.
 43. A field block for use with a nuclear density gauge comprising an absorption element, wherein said absorption element is capable of simulating at least one known density when subjected to analysis using the nuclear density gauge, wherein said field block further comprises an enclosure, and wherein said absorption element is translatable from a first operative position to a second operative position, and wherein said enclosure includes a substantially hollow region configured to allow said absorption element to translate in one or more of a linear or rotatable manner within said enclosure.
 44. A field block according to claim 43, wherein the nuclear density gauge detects two backscatter measurements, a first measurement corresponding to said absorption element positioned in said first operative position and a second measurement corresponding to said absorption element positioned in said second operative position.
 45. A field block according to claim 44, wherein the nuclear density gauge detects two different measurements, a first measurement corresponding to a direct transmission measurement with said absorption element positioned in said first operative position, and a second measurement corresponding to a backscatter measurement with said absorption element positioned in said second operative position.
 46. A field block according to claim 43, wherein said absorption element is mounted to said field block such that it is translatable from a first operative position to a second operative position in response to an externally accessible lever. 